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I’ve had the armor for a few weeks, so I’ve taken my time cutting, sanding, and getting it to *look* right. After some trial and error, I finished the horns on the shoulder pieces. 2 pieces of 3mm sintra glued together, cut out, sanded, and beveled to give that *sharp* edge look. 2 screws hold each horn in from the underside.

Helmet: I’ve mocked up most of the horns with paper, cut them out of sintra (2 pieces of 3mm), sanded and smoothed the edges, Since taking that pic, I’ve contoured the bottom edge so it fits better on the curve of the helmet, and attached each horn with some screws. I’ve only done the 6 large horns – still need to do the 4 smaller ones around the middle of his helmet.

I’m still working on attaching the armor to the vest. My Jango uses snaps, but I’m experimenting with Chicago screws. I picked up a pack of 100 here: Results for chicago screw - MyBinding.com - Binding Machine GBC Laminator Ibico Book BindingI used 1/4” screws, but I think that 3/8” might give better closure when going through thicker stuff. To attach them to the armor, I took a piece of sintra, and used my heat gun to give it the right curve to match the armor. After that, I drilled a hole for the post, and sanded down (countersunk) the backside of the sintra. This way, the post comes through the hole, and the sintra can still sit flush with the backside of the armor piece. After using some PVC cement to glue it in, viola! Chicago screw post attached to the back of your armor!

I lined up the armor on the vest where I wanted it, and marked where the holes should be to allow the Chicago screw to pass through. I cut a small hole, and then added a grommet to ensure that the hole doesn't tear anymore. When I’m ready to attach the armor, I slide the post of the Chicago screw through the grommet, and secure on the other side with either a washer, or another piece of curved sintra, and then the screw end of the Chicago screw.

Leather waist wrap that secures with clips, and then has a flap over it to cover. Mine is black, but this is the same process:

Belt and boxes: I’m hand-making these out of sintra. I took a piece of sintra 3in x 24in, and used my heat gun to give it a large curve so it would wrap around my body. I used a 5-gallon bucket from a local hardware store as a form to keep it straight. I cut out the individual boxes out of sintra, and have given most of them (not the half inch or quarter inch ones) the same curve using the heat gun and bucket. The center box and 1 on either side have holes cut in them. After finding the center of the larger piece, I started gluing on the boxes using superglue. After a few boxes, I added holes to secure it to the waist wrap using Chicago screws, grommets, and washers. I made sure to line up the bottom holes accordingly so they could hold my cod piece on as well. Once I test fit the screws to make sure they line up, I put a little dab of super glue on the post end to secure it from spinning, then it’s covered by the remaining belt boxes, and is out of sight.The edges of the boxes are a little rough. Once this piece is complete, I'm going to sand / fill so that the tops and bottoms of the belt boxes are more even. This piece will cover the front half of the waist wrap, and be secured by 8 Chicago screws. As soon as this piece is completed, I will make 2 more to cover the back half.

Added the 2 3" boxes on either side (the first one covered up the middle chicago screws), and lined up and drilled holes for the outer screws. These will be covered by the 2" boxes with the 1" squares cut out.

After doing one side, I found that the overall curve of the belt wasn't curved enough, and it started to stress and crack a little. I put a little superglue along the crack to seal it, but I think I'll have to give it some more time with my heat gun to get it to fit just right.

Spent some time with the heat gun and fixed the front half of the belt. Did the screws and grommets for that, so it's done (front half, from right hip to left hip). Glue is drying. Back of the belt still to do.

Also, did a whole bunch of grommetting on the vest. Back, collar, 2 shoulders, 2 chest, and the center diamond. Basically, everything except the stomach piece - (had issues with one of the screws).

Scratch that.... all the armor is supposed to be JUST ABOUT touching...
Which means.... I'll need a whole new vest. 29 grommets and a few yards of pleather down the drain.

Good thing is... I can put snaps on my shoulders instead of Chicago screws / grommets. The more I think about it, it would be *easier* for travel and storage if the shoulders are easily removable after a troop. (its the way my Jango travels).

Haven't updated in a while, so here's where I'm at. Nothing really "picture-worthy" but still progress is being made.

[li]Blasters are being painted. Needing a couple coats. 1 or 2 more, and a clear coat, and they should be done[/li]
[li]New Vest done[/li]
[li]Plates attached to the new vest (closer this time)[/li]
[li]Horns adjusted slightly[/li]
[li]Straps added for boot armor and handplates[/li]
[li]Gauntlets finished (magnet closure)[/li]
[li]Jetpack parts received. Haven't started that yet[/li]

All the parts (except the jetpack and backplate) go off to paint this weekend. I'll post pics when they return.

I've abandoned the sintra belt. It just doesn't look right, and isn't hugging my body the way I want. I've commissioned a friend to make me a leather one.

Hi, I'm loving this thread and want to see more. I'm working on my own death watch commando amour and am wondering if anyone can help me out. Im using the wof helmet templates and modifiying them to match the death watch helmet. Can anyone tell me the length of the t visor space on the death watch helmet as it is longer than fetts and i can find any dimensions anywhere. thanks guys

Big update. Took some time off for the holidays, and now I'm back at it.

Forearms, gloves, and handplates.

Thigh plates with Chicago screw attachment:

The thighs and shins are attached this way. The knees have magnets in them, and then corresponding magnets sewn inside the flightsuit so they can just *pop* on and still have a tight hold.

Thighs, knees, and Shins:

Since the thighs and shins are "permanently" attached to the suit (via Chicago screws), it travels like this:

Today's critique:
- Knees and shins could use some separation. They seem a little too close to each other.
- Legs and short sleeves on the flightsuit are a little too baggy for this character. They should be taken in a bit.

Still left to do on this costume:
- Padding in holsters for blasters
- Padding in helmet
- Helmet visor
- Strapping for boot armor
- Better neck closure on flightsuit.